Building panel enclosures for valley and hip structures

ABSTRACT

Prefabricated enclosure tip panels and a method of manufacturing the tip panels for enclosing valley and/or hip areas. The tip panel at one longitudinal end is beveled at an angle &#39;&#39;&#39;&#39;a&#39;&#39;&#39;&#39; which angle is dependent upon the relative angle between the two sections at the valley and/or hip joint. The other longitudinal end is adapted for interengagement with a standard panel. A method of manufacturing the tips include segmenting a standard panel at the angle &#39;&#39;&#39;&#39;a&#39;&#39;&#39;&#39; to form a first valley tip panel and a first hip tip panel. A second standard panel is then segmented at an angle (180*-a) to form a second valley tip panel complementary to the first valley tip panel and a second hip tip panel complementary to the first hip tip panel. The tip panel segments are adapted to be joined in combination along the valley line and/or hip line to form a complete valley and/or hip construction and to engage standard panels. A valley flashing may be positioned along the valley center line and extend laterally relative to the center line beneath the valley tip panels to provide a hidden run-off path for water on the roof.

Kongh et al.

[ 1 May 8,1973

[54] BUILDING PANEL ENCLOSURES FOR VALLEY AND HIP STRUCTURES [73]Assignee: Ditz-Crave, San Francisco, Calif.

[22] Filed: Dec. 20, 1971 [21] Appl. No.: 210,039

Related U.S. Application Data [62] Division of Ser. No. 856,235, Aug. 7,1969, Pat. No.

111,690 12/1928 Austria ..52/l3 Primary ExaminerI-Ienry C. SutherlandAttorneyPaul D. Flehr et al.

[57] ABSTRACT Prefabricated enclosure tip panels and a method ofmanufacturing the tip panels for enclosing valley and/or hip areas. Thetip panel at one longitudinal end is beveled at an angle 11" which angleis dependent upon the relative angle between the two sections at thevalley and/or hip joint. The other longitudinal end is adapted forinterengagement with a standard panel. A method of manufacturing thetips include segmenting a standard panel at the angle a to form a firstvalley tip panel and a first hip tip panel. A second standard panel isthen segmented at an angle (l80a) to form a second valley tip panelcomplementary to the first valley tip panel and a second hip tip panelcomplementary to the first hip tip panel. The tip panel segments areadapted to be joined in combination along the valley line and/or hipline to form a complete valley and/or hip construction and to engagestandard panels. A valley flashing may be positioned along the valleycenter line and extend laterally relative to the center line beneath thevalley tip panels to provide a hidden run-off path for water on theroof.

3 Claims, 6 Drawing Figures Patented May 8, 1973 3,731,438

2 Sheets-Shea t 1 4 52 5o 49 iFiG.l

I5 2 I2 43 \ags \WRNR I3, I5 zo COMMON RAFTER Patented May 8, 1973 2Shee ts-Sheet z Fl G.5

BUILDING PANEL ENCLOSURES FOR VALLEY AND HIP STRUCTURES RELATEDAPPLICATION This Application is a division of my co-pending applicationSer. No. 856,235, filed Aug. 7, 1969, for Building Panel Enclosure ForValley and Hip Structures now U.S. Pat. No. 3,696,570.

BACKGROUND OF THE INVENTION This invention relates to a prefabricatedenclosure panels, incorporating commonly used surfacing materials forenclosing roof and sides of building structures.

A preferred covering or enclosure material for building exteriors hasbeen shakes applied over a sheathing and waterproofing membrane. Suchmaterials are commonly used for roofing and siding of buildingstructures. A considerable number of prior attempts have been made toprovide shake roofing or siding which would avoid some or all of theconventional steps of bundling shakes and shingles, transporting thebundles to the site, applying sheathing, applying waterproof membrane,hoisting the bundles to the roof or scaffold,

breaking the bundles and then applying the shakes, one at a time. Thesenumerous steps involve risk of damage to the building materials andconsiderable installation time and expense. Heretofore, prefabricatedpanels have been designed overcoming these problems to a substantialdegree. Such prefabricated panels have proven highly satisfactory anddesirable for applying shake roofing and siding. Such panels arediscussed and described in U.S. Pat. No. 3,440,777 granted Apr. 29, 1969to Otis M. Martin and in United States Patent application Ser. No.793,865 and 775,731.

Though prefabricated panels are presently in use, it has been found thatdeficiencies remain in providing panels to enclose hip and valley areas.Such hips and valleys are generated by the intersection of two planeshaving different relative slope angles. For example, in anL-shapebuilding, when the two roof sections meet there is a valleyand/or hip sectionformed at the point of intersection. In fact,depending on the building layout, there are. numerous possible hipand/orvalley combinations A standard panel having a straight terminaledge is notadequate to accommodate the angle at the point ofintersection. Accordingly, on-site custom fitting of panels and/orindividual shingles is frequently necessary to enclose the valley andhip areas. Also, it is desirable that where valleys are formed that theflashing forming the run-off canal be hidden from view whilediscouraging undesirable debris from the-flashing.

SUMMARY OF THE PRESENT INVENTION The present invention providesprefabricated enclosure tip panels and a method of manufacturing the tippanels for enclosing valley and/or hip areas about two engaging buildingstructure sections of differing slopes. The teachings enable a shakeroof to be builtwith open valleys or with closed valleys and hiddenflashing. The hip and/or valley tip panel segments may be manufacturedfrom standard panel utilized on the same roof section of they can bemade as a separate manufactured item. The invention further teaches inmanufacturing the tip panels from standard panels, a hip tip panel and avalley tip panel may be generated from a single common standard panel soas to utilize the entire standard panel.

In an exemplary embodiment of the tip panels, a sheathing member,weather membrane and shakes are cut at an angle coinciding with theangle of the hip or valley line. The sheathing member, weather membraneand shakes are secured in combination to form a tip panel with a bevelededge which may be placed in parallel with the hip or valley line. Thetip panel is further adapted for standard aligned engagement with astandard horizontally positioned panel on the roof section and foraligned engagement with a vertically positioned panel on the roofsection.

ln an exemplary method of manufacturing the panel tips, a guide-securingstrip of weather resistant wood is placed on top of a standard shakeroofing panel. The strip is placed over the shakes at an angle a"dependent upon the angle of the valley line. The panel is then cut alongthe edge of the strip. The two resultant sections form a first valleytip panel and a first hip tip panel. A second guide-securing strip isthen placed on top of a second shake roofing panel over the shakes at anangle b where b" is in the order of a. The second panel is out along theedge of the strip to form a second valley tip panel segment and a secondhip tip panel segment, respectively, complementary to the first valleytip panel and thefirst hip tip panel. Accordingly, the area about thehip may be enclosed by joining and securing a plurality of the hip tippanels along the hip line and the valley may be enclosed by joining andsecuring a plurality of the valley tip panels along the valley line.Each tip panel carries a standard longitudinal terminal end to allowaligned engagement with horizontally positioned standard panels. Theguidesecuring strips are retained in place to secure the otherwise looseshake segments in place.

In forming a closed valley with hidden flashing, a pair of strip membersare secured in place over jack rafters. The strips extend the fulllength of the valley in parallel with the valley line and laterally fromthe valley rafter. A valley metal flashing is secured to both stripsalong the valley over the valley rafter. A center strip is laid on topof the flashing along the valley line. The roof structure may then bebuilt up by placing the beveled ends of the valley tip panels on thecenter strip and securing the valley tip panels in place. Consequently,as valley tip panels are secured in place along and on both sides of thevalley line the flashing is hidden. At the same time, there is provideda spacing intermediate the flashing and the bottom side of the valleytip panels to allow for water run-off.

BRIEF DESCRIPTION OF THE DRAWINGS F IG. 1 is a perspective, partiallysectioned view of a partial enclosed roof of an L-shape buildingstructure forming a valley and a hip and utilizing tip panels inaccordance with the teachings of the present invention.

FIG. 1A diagrammatically illustrates roof framing structure includingthe angle relationship between roof ridges, valley lines and hip lines.

FIG. 2 is a perspective view of a tip panel and a standard roofingpanel.

FIG. 3 illustrates a top view of a standard panel of FIG. 2 prior tobeing segmented at a desired angle to form a hip tip panel and a valleytip panel for enclosing the hip and valley areas of FIG. 1.

FIG. 4 is a top view of a standard panel of FIG. 2 prior to beingsegmented at a desired angle to form a hip tip panel and a valley tippanel segment complementary to the tip panels of FIG. 3.

FIG. 5 illustrates an enlarged cross-sectional view along the line 5-5of FIG. 1 illustrating the flashing and enclosed valley structure.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to the drawings, FIG.1A diagrammatically illustrates roof framing with terminology as used inthe art. FIG. 1 illustrates in perspective a section of an L- shapebuilding having two gable roof sections, referred to by the generalreference characters 2 and 4. The section of FIG. 1 may be viewed aswithin the broken line block of FIG. 1A. The sections 2 and 4 intersectto form a hip and a valley. The roof section 2 has two subsections 2Aand 23 joined at an angle to form a ridge 6. The roof section 4 has twosubsections 4A and 4B joined at an angle to form a ridge 8. The roofsubsections 2A and 4A come into integral relationship to form a valleyhaving a vertex referred to as a valley line 10. The roof subsections 2Aand 4A come into integral relationship to form ahip having a vertexreferred to as a hip line 12. FIG. 1A further illustrates the angularrelationship between the ridges 6, 8 and line 10, 12. A plurality ofrafters 13 extends from the ridge 6 tosupport the subsections 2A, 2B anda plurality of rafters 14 extends from the ridge 8 to support thesubsections 4A, 4B.

Enclosing the roofing structure of the roof sections 2 and 4 may berealized by use of prefabricated roofing enclosure panels 15 of uniformdimensions and select surfacing materials joined in combination. Theindividual panels 15 illustrated in detail in FIG. 2 are prefabricatedto assume a uniform patters such that when in aligned engagement auniform unitary appearange is provided. The panel 15 includes a base inthe form of sheathing member 15, e.g. plywood having superimposedthereon a membrane 17 of felt, asbestos orother waterproof, fireproof orother desired nature. Over the membrane 17 is secured a veneer strip 18and a plurality of spaced apart shakes 19. The top terminal ends oftheveneer strip 18 and the shakes l9 abut a furring strip 20 with themembrane 17 folded back over the strip 20. The furring strip providesfor aligned abutting relationship with an upper panel 15. Near thelongitudinal ends of the panels 15, the veneer strip 18 is exposedwithin a void space adapted to receive a shutter shingle after thepanels are positioned in alignment on the roofing structure. Panelssimilar to the panel 15 are described in the aforementioned patentapplication Ser. No. 793,865. Other panels are described in theaforementioned patent, the other aforementioned patent application andin the patent application of the present inventors entitled, Panel forSurfacing Buildings, filed concurrently herewith.

As illustrated, the full panels 15 are of rectangular shape with squareends at the longitudinal terminal ends. These panels 15 are not adaptedto accommodate the areas about the valley line 10 and the hip line 12since the vertex lines 10 and 12 are not normal to the associated ridgelines. To accommodate enclosing the roofing structure about the hip andvalley lines, enclosure tip panels, having one longitudinal terminal endbeveled to coincide with the angle of the valley or hip vertex line isprovided. The other longitudinal terminal end is adapted for alignedengagement with a standard panel 15 and the longitudinal running edgesare adapted for aligned engagement with other tip enclosure panels orstandard panels 15. In FIG. 2, adjacent to the standard panel 15 isdepicted a tip enclosure panel 15A adapted to be used to enclose theroofing subsection 28 about the valley line 10. The materials of the tippanel 15A coincide with those of the panel 15 and the dimensions areselected to accommodate aligned engagement with the panels 15. The tippanel 15A includes a sheathing member 16A of the same width andthickness as the sheathing member 16. One longitudinal terminal end ofthe sheathing member 16 is cut at an angle a coinciding with the angleof the ridge 6 to the valley line 10. A membrane 17A is superimposed onthe sheathing member 16A which membrane 17A is of the same material asthe membrane 17. Over the membrane 17A is secured a veneer strip 18A anda surfacing material in the form of a plurality of spaced apart shakes19A. The terminal ends of the veneer strip 18A and the shakes 19A abut afurring strip 20A with the membrane 17A folded back over the strip 20A.The membrane 17A, veneer strip 18A and shakes 19A are all cut an theangle a to form a valley panel tip which tip will accommodate the valleyline and provide aligned engagement with a standard panel as illustratedin FIGS. 1 and 2. The bottom edge of the shakes 19A are all insubstantial alignment and the longitudinal edges of the shakes 19A aresubstantially parallel to one another. As illustrated in FIG. 1, aplurality of the tip panels 15A may be secured along the valley line 10.Similarly, a plurality of valley tip enclosure panels 15C may be formedto complement the tip panels 15A to enclose the subsection 4B about thevalley line 10. In this instance, the sheathing membrane, veneer stripand shakes are cut at an angle c coinciding with the angle of the ridge8 and the valley line 10. Similarly, hip tip enclosure panels 158 and15D maybe formed to enclose the subsections 2A and 2B, respectively,about the hip line 12.v The hip panel tip 1513 may have one longitudinalterminal end assuming an angle b coinciding with the angle between theridge 6 and the hip line 12. The hip panel tip 15D may have onelongitudinal terminal end assuming an angle d coinciding with the anglebetween the ridge 8 and the hip line 12. Viewing FIGS. 1 and 2, it maybe noted that the tip panels 15A, 15B, 15C and 15D all provide foraligned engagement with standard panels 15 and with adjacent tip panels.The bottom edges of the shakes of the tip panels are all in substantialalignment with the shakes of the panels 15 on the associated roofingsubsection to provide a uniform pattern, and the longitudinal runningedges of the individual shakes on the tip panels and full panels on theindividual subsections 2A, 2B, 4A and 4B are substantially parallel toprovide a uniform appearance.

FIGS. 3 and 4 illustrate a method of manufacturing tip panels. FIG. 3illustrates the standard panel 15 with a guide-secure strip 20 ofweather resistant material,

e.g. redwood, cedar, etc. stapled across the top of the shakes 19 by aplurality of staples 20 or other acceptable fastening means. A staple 21is positioned to join each shake 19 intersected by the strip 20. Thestrip may be in the nature ofa lath strip of X l% inches. Relative tothe top longitudinal running edge, the strip 20 forms an angle a and anangle b. The angle a" is selected to coincide within a common plane theangle formed by the ridge 6 and the valley line 10. Also, in thisembodiment, the angle b" coincides within a common plane the angleformed by the ridge 6 and the hip line 12. The length of theguide-secure strip 20 is selected to extend from the bottom edge of theshakes 19 to a point coinciding with the end of the overlap ofa panelplaced in vertical alignment when secured to the roofing structure. Thepanel is then cut along the right edge of the strip to form a panelsegment 15A and a panel segment 158. As illustrated by the two naillines 22, the shakes 19 of the panel 15 are commonly secured near thetop edge such that the overhang of a vertically adjacent panel extendsover the nail lines. Consequently, the lower areas of the shakes 19 arenot secured. The strip 20 remains with the tip panel 158 and secures theotherwise unsecured shake segments in place while simultaneouslyfunctioning as a guide. The segment 15A serves as a first valley tippanel while the segment 15B serves as a first hip tip panel aspreviously discussed. To form the complementary of the tip panels 15Aand 158 a second panel 15 is utilized. As illustrated in FIG. 4, anotherstrip 20 is placed across the second panel 15 to form a pair of angles 0and (1" relative to the top longitudinal running edge. The strip issecured by staples 21. The angle 0 coincides with the angle withincommon plane between the ridge 8 and the valley line 10. Also, in thisinstance since there is a common hip panel generated with the valleypanel, the angle d" coincides with the angle formed by the ridge 8 andthe hip line 12 within a common plane. The second panel 15 is then cutalong the strip 20 to form the panels 15C and 15D. The panel 15C servesas a second valley tip panel complementary to the tip panel 15A and thepanel 15D serves as a second hip tip panel complementary to the tippanel 153. Viewing FIG. 1, the various tip panels may be used incombination to enclose the roof structure about the valley line 10 andhip line 12. The tip panels fall in alignment forfull panels 15 and maybe interengaged with a common shutter shingle 24.

Viewing FlG. 1, while water will run away from the hip line 12 of theenclosed roof, water will run to the valley. Accordingly, it isnecessary to provide a trough at the valley to accommodate run-offwater. Though open valleys adequately provide for run-off, aestheticallyhidden valley structures are more desirable since the flashing is notvisible from the exterior. FIGS. 1 and 5 illustrate the structure of thehidden flashing within the closed valley of the present embodiment. Thestructure includes a pair of lateral support strips and 32, e.g. 1 inchby 6 inches positioned on opposite sides of and parallel to the valleyline 10. The strip 30 rests over and is connected to a plurality ofrafters 14 of the roofing subsection 4B and the strip 32 rests over andis.connected to a plurality of rafters 13 of the roofing subsection 28.The strips 30 and 32 extend from the bottom edge of the roof subsections4B and 28 to the ridges 8 and 6 to coincide with the length of thevalley. A valley rafter 34 runs along the valley line 10 interconnectingthe subsections 2B and 4B. Extending between the strips 30 and 32 andover the top edge surface of the rafter 34 is a metal flashing member36. The metal flashing member is preferably cut from sheet metal such ascopper, galvanized steel or the like and extends the full length of thevalley line 10 and the strips 30 and 32. The flashing 36 is secured tothe strips 30 and 32 by standard securing means such as nails 38. Thelateral positioning of the strips 30 and 32 may be selected to allow theflashing to extend laterally from the valley line a select distance inaccordance with local building codes, e.g. 11 inches. Directly over theflashing 36 and the valley rafter 34 is a center valley strip member 40,eg a 2 inches by 4 inches board to form a sandwich type structure withthe flashing 36 intermediate the rafter 34 and the strip member 40. Thecenter strip 40 is not nailed in place so as to avoid violating thewaterproofintegrity of the flashing.

To close the subsection 28 about the valley line 10 a plurality ofvalley tip panels 15A may be secured to adjacent rafters 13 in verticalalignment from the bottom of the subsection 2B to the ridge 6 with thebevel edge surfaces supported on the center strip 40. The segments 15Amay also be secured to the strip 32 within the area adapted to receive ashutter shake and/or along the nailing line 22. To close the subsection43 about the valley vertex 10 a plurality of valley tip panels 15C maybe secured to adjacent jack rafters 14 in vertical alignment from thebottom of the section 48 to the ridge 8 with the bevel edge surfacessupported on the center strip 40. The segment 15C may also be secured tothe strip 30 within the area adapted to receive a shutter shingle and/oralong the nailing line 22. The panel segments 15A and 15C may be securedto the center strip 40 by nails 42 or other securing means with thenails 42 positioned within the nailing lines 22. The overhang from thevertically adjacent tip panel extends over the nails 42. Again, thenails 42 preferably do not protrude through the strip member 40. Asillustrated, the center strip member 40 supports the panel segments 15Aand 15C above the flashing 36 to provide a triangular shaped spacingbeneath the tip panels. Accordingly, run-off water is able to seep tothe flashing 36 between adjacent tip panels 15A and 15C and run to thebottom of the valley. At the same time, the panels 15A and 15C are inproper position and alignment to engage full panels 15 to completeenclosing of the roofing subsections 2B and 4B.

To close the subsection 2A about the hip line 12 a plurality of hip tippanels 158 are secured to adjacent jack rafters 13 in vertical alignmentfrom the bottom of the subsection 2A to the ridge 6 with the bevel edgesurfaces on the hip line 12. To close the subsection 4A about the hipline 12 a plurality of hip tip panels 15D are secured to adjacent jackrafters 14 in vertical alignment from the bottom of the section 4 to theridge 8 with the bevel edge surfaces on the hip line. The hip panel tipsmay be secured to a hip rafter 48 by fastening means such as nails 49extending through the guidesecure strips 20. The guide-secure strips 20being selected so as to extend from the bottom edge of the shakesegments to the edge of the overhang area allows for abutting alignmentof the guide-secure strips 20 as vertically adjacent hip tip panels aresecured in place.

After the subsections 2A and 4A are enclosed, a segment of felt S orother membrane material similar to that of the membrane 17 and aplurality of ridge shakes 52 may be secured along the hip line 12 tocover the strips 20. The end result, as depicted in FIG. 1, is a unitaryenclosure with the surfacing material (shakes) assuming a uniformpattern.

Accordingly, there is taught herein prefabricated tip panels and methodof manufacturing such tip panels to allow for enclosing hip and valleyroof sections requiring no or minimal on-site custom fitting. The tippanels are adapted for interengagement with standard panels to providefor rapid and easy installation. At the same time, there is taught amethod of providing a closed valley structure in which the flashing isnot visible from the exterior. Though the discussion has centered abouta method of generating a hip closure panel segment and i a valleyclosure panel segment from a common panel it will also be apparent tothose skilled in the art that two valley or hip closure panel segmentsmay be generated from a common panel. For example, viewing the panel ofFIG. 3, the desired segment 15A or 158 is retained. Then over the othersegment a strip is secured at the desired angle. For example, if thevalley tip panels 15A and 15C are desired from a common standard panel,the panel 15 of FIG. 3 is severed along the strip 20. Then over thepanel segment 15B is secured a strip 20 at the angle 0 and then sawn.

Iclaim:

1. An enclosed valley section of a roofing structure comprising, incombination:

a valley rafter extending along the valley line formed by theintersection of the planes of the first and a second roof structuresection of differing plane angles;

a first side strip extending parallel with and lateral to the valleyline along the first roof section;

a second side strip extending parallel with and lateral to the valleyline along the second roof section;

a flashing member engaging each side strip and extending over saidvalley rafter;

a center valley strip member extending along the valley line over theflashing member;

a first valley closure tip panel secured to the first roof section andextending over the center valley strip, the first valley closure tippanel having a beveled edge coinciding with the angle of the valley anda longitudinal terminal end adapted for aligned engagement with astandard enclosure panel on said first section; and

a second valley closure tip panel secured to the second roof section andextending over the center valley strip, the second valley closure panelhaving a beveled edge coinciding with the angle of the valley and alongitudinal terminal end adapted for aligned engagement with a standardenclosure panel on said second roof section.

2. The enclosed valley of claim 1 in which the first and the second sidestrips, the center valley strip and the flashing member all extendsubstantially the entire length of the valley; and

a plurality of first and second valley closure tip panels are placed inaligned engagement on opposite sides of the center valley stripsubstantially the full length of the flashing member.

3. The enclosed valley of claim 2 in which first side strip is securedto rafters of the first roof section structure; the second side strip issecured 'to rafters of the second roof section; and the first and thesecond valley closure tip panels are secured to the center valley strip.

1. An enclosed valley section of a roofing structure comprising, incombination: a valley rafter extending along the valley line formed bythe intersection of the planes of the first and a second roof structuresection of differing plane angles; a first side strip extending parallelwith and lateral to the valley line along the first roof section; asecond side strip extending parallel with and lateral to the valley linealong the second roof section; a flashing member engaging each sidestrip and extending over said valley rafter; a center valley stripmember extending along the valley line over the flashing member; a firstvalley closure tip panel secured to the first roof section and extendingover the center valley strip, the first valley closure tip panel havinga beveled edge coinciding with the angle of the valley and alongitudinal terminal end adapted for aligned engagement with a standardenclosure panel on said first section; and a second valley closure tippanel secured to the second roof section and extending over the centervalley strip, the second valley closure panel having a beveled edgecoinciding with the angle of the valley and a longitudinal terminal endadapted for aligned engagement with a standard enclosure panel on saidsecond roof section.
 2. The enclosed valley of claim 1 in which thefirst and the second side strips, the center valley strip and theflashing member all extend substantially the entire length of thevalley; and a plurality of first and second valley closure tip panelsare placed in aligned engagement on opposite sides of the center valleystrip substantially the full length of the flashing member.
 3. Theenclosed valley of claim 2 in which first side strip is secured torafters of the first roof section structure; the second side strip issecured to rafters of the second roof section; and the first and thesecond valley closure tip panels are secured to the center valley strip.